We are delighted to share that MinTech was recently featured in the Innovation spotlight of California Business Journal.  Read on for a preview of the article.

DUST BUSTER

MinTech’s Unique Organic Dust Control Substances Reduce Airborne Dust by a Staggering 97 Percent

Before Harry Heydorn joined material-handling company MinTech, he worked as an engineer for a major coal-fired power utility company, where he faced a plague that became his business to eradicate: dust.

Every day, workers at the power plants moved coal out of the piles and conveyed it through the plant where it was crushed into a powder and then burned. They transferred tens of thousands of tons of coal an hour on conveyor belts moving 45 miles an hour, generating clouds of dust at every transfer point, and every time it was ground or pulverized.

Uncontrolled, most sources of dust in plants and mining operations lingers in the air, and is breathed into the lungs of workers, causing them major health problems such as silicosis and the infamous black lung disease.

“The main reason we’re eliminating and reducing dust is for the people, whether it’s the operators making the product, or somewhere downstream where there may be a transfer, or where they’re transloading materials, all the way down to the end users and any communities who could be affected,” Heydorn says.

MinTech recently launched MinTerra, a new and unique line of dust control solutions for the fertilizer industry, which like the coal industry, must manage the levels of dust created by material handling processes in order to protect workers and communities alike.

MinTerra DustAid helps reduce fertilizer dust by 97%

Read the entire article here: https://calbizjournal.com/dust-buster/.

Learn more about MinTech’s MinTerra solutions here: https://mintech.com/minterra/.

Soil management is a key part of agriculture Best Management Practices (BMPs), within which fertilizer application is vital to increasing crop yields and sustaining them at high levels.  Without it, the agricultural impact could be significant. One long-term field study based in Missouri found that 57% of grain yield resulted from lime and fertilizer application.  And another study found that corn yields could decline by 40% when fertilizer is not used[1].  If there’s an even greater nutrient deficit, that yield reduction could be more, having a severe impact on farm revenues and on meeting global food demand, which is expected to increase by at least 59% by 2050[2].

It’s easy to see that fertilizer plays a key role in boosting crop yield, driving farmer incomes, and feeding a growing population; however, applying fertilizer is not as straightforward or simple as it sounds.  There are many elements that can affect the efficacy of fertilizer, including even distribution during the application process.

Uniform fertilizer distribution is key to boosting crop yield.

Why uniform fertilizer application is important

Simply put, uniform fertilizer application is the only way to guarantee that vital nutrients are equally distributed to every crop.  Conversely, uneven application can cause irregular growth, discoloring among crops, decreased yield, and low crop value.

Uniform fertilizer application is not just a preference or a “nice to do” – it is key to proper soil management.

5 factors that affect even fertilizer distribution

There are five key factors that influence fertilizer application to a great degree.

1. Granule uniformity

Granule uniformity is a crucial contributor to quality fertilizer.  The importance of uniformity is twofold – it facilitates consistent nutrient distribution and even fertilizer application.

Granule uniformity is crucial: The more uniform the granules, the more likely they are to contain equal amounts of nutrients.

The more uniform the granules, the more likely they are to contain equal amounts of nutrients[3].  The less uniform the granule, the less predictable.  A 2005 study from the American Society of Agricultural and Biological Engineers[4] found that there was virtually no difference in the chemical makeup of fertilizer granules as long as they were the same size.

In addition to inconsistent nutrient make-up, when the granules are different shapes and sizes, the fertilizer doesn’t flow as easily, making an even spread more difficult to achieve.  Uneven distribution means some crops will receive nutrition while others are neglected.

Low uniformity is more likely to happen once fertilizer ages because the granules can degrade as they get older.  To improve the chances your fertilizer granules are uniform, use fertilizer as close to the date of manufacture as possible.  The closer the production date, the higher the likelihood the fertilizer will be in peak shape.  Also — though harder to control — purchasing fertilizer made from the same manufacturing batch is a great way to ensure consistency in the shape and size of your granules[5].

2. Caking and clumping

Caking is a sign that humidity has invaded your fertilizer.  Most farmers understand the downside of caked or clumped product – it’s less effective and, in many cases, its quality is compromised.  Should you need to apply caked fertilizer, an even spread is nearly impossible and can result in overfertilization and loss of important crop nutrients.

Caked fertilizer causes a buildup of residue in your fertilizer spreader, especially in spots like the spiral cones, the agitator, and the impeller.  This means that you’ll need to use more force to achieve the same volume of spread, and you’ll likely see a reduced delivery rate[6].  You’ll also need to recalibrate your spreader more frequently.  You may even need to use an abrasive or solvent to effectively remove the buildup.  All these issues result in additional time, resources, and financial costs and still do not ensure even fertilizer application.

3. Micronutrient/macronutrient segregation

In nutrient segregation, micronutrients and macronutrients are either unevenly bound or not bound to each other at all.  If unbound, the micronutrients often settle to the bottom of the product, so when the fertilizer is applied, the nutrients are not evenly distributed across the planting area.

There are three primary types of nutrient segregation[7]:

1. Ballistic segregation – The spreader tends to toss heavier granules further, which comes into play when the granules are blended from particles that are different sizes or weights.
2. Coning segregation – Heavy granules fall to the bottom of the fertilizer pile, so granules made from materials of different sizes, shapes, and densities are likely to separate.
3. Sifting segregation – Fertilizer sifting tends to happen during long periods of transport.

Regardless of the type of segregation, the unbinding of macronutrients and micronutrients leads to nutrient-deficient crops and lower yields.

4. Subsoil compaction

Compaction may help strengthen soil, but the more compacted it is, the more difficult it is to spread fertilizer evenly.  With a lot of compaction, fertilizer may not penetrate the soil[8] or reach all crops, as it bounces around and lands in random ways.  It’s critical that farmers assess this early on and address root-soil dynamics and nutrient movement to ensure the most even distribution possible.

5. Fertilizer spreader

The fertilizer spreader certainly plays an important role in even fertilizer application.  First, you need to choose the right spreader.  There are three main types to consider – rotary spreaders, drop spreaders, and liquid spreaders.  The one you decide on depends on the amount of land you need to cover and the type of fertilizer you are using.  Drop and liquid spreaders tend to work best for even, precise applications[9].   Rotary spreaders spread fertilizer over longer distances but do not follow any particular flow patterns.

Selecting the right spreader and using the right maintenance and application procedures directly impact successful fertilizer application.

After selecting the spreader, be sure to observe application best practices, such as using the right speed and gear for constant application, driving the correct working width, and heeding field margins to ensure you load enough fertilizer.  Also, regular maintenance is key to prevent buildup or breakdown of parts.

Conclusion

Uniform fertilizer distribution is one of the best ways to protect and improve your crop yield. While not all factors can be completely controlled, by taking the time to adhere to BMPs, manage your fertilizer quality, and maintain your spreader, you can help reduce unpredictable results.

MinTech can help, too.  The products in the MinTerra line are all designed to prevent the issues that make even application difficult.  DustAid controls fertilizer dust so product isn’t weakened or wasted, CakeBrake provides long-lasting anti-caking support, and MicroBind improves the durability and solubility performance of fertilizer blends.

Visit mintech.com/minterra/ to learn more.

[1] Mikkelsen, Rob. (2019). Understanding Fertilizer and Its Essential Role in High-Yielding Crops. Retrieved from: https://www.cropnutrition.com/understanding-fertilizer-and-its-essential-role-in-high-yielding-crops?7258dda8-3796-4e4a-aa05-5362a445b6ab=0

[2] Elferink, Maarten and Schierhorn, Florian. (April 7, 2016). Global Demand for Food Is Rising. Can We Meet It? Retrieved from: https://hbr.org/2016/04/global-demand-for-food-is-rising-can-we-meet-it

[3] Isleib, Jim (December 29, 2016). Pros and cons of granular and liquid fertilizers. Retrieved from: https://www.canr.msu.edu/news/pros_and_cons_of_granular_and_liquid_fertilizers

[4] Smith, D.B., Willcutt, M.H., and Diallo, Y. (2005). Uniformity Of Size And Content Of Granular Fertilizers. Retrieved from: https://elibrary.asabe.org/abstract.asp??JID=3&AID=18562&CID=aeaj2005&v=21&i=4&T=1

[5] Searle, Sam. (June 1, 2018). 5 Tips For Effective Fertiliser Spreading. Retrieved from: https://www.rataequipment.com/blog/5-tips-for-effective-fertiliser-spreading

[6] Parish, Richard L. (1998). Granular Spreaders: Selection, Calibration, Testing, and Use. Retrieved from: https://www.lsuagcenter.com/NR/rdonlyres/D9458BB7-D852-40B4-B434-5A6FC0C43E0E/3925/B868.pdf

[7] Simplot Partners. (2019). The Benefits of Homogeneous Granular Fertilizer. Retrieved from: http://partners.simplot.com/education/2018/03/08/benefits-of-homogeneous-granular-fertilizer

[8] Searle, Sam. (June 1, 2018). 5 Tips For Effective Fertiliser Spreading. Retrieved from: https://www.rataequipment.com/blog/5-tips-for-effective-fertiliser-spreading

[9] Framing Nailers Guide. (2019). 4 Types of Fertilizer Spreaders Explained by Real User. Retrieved from: https://framingnailersguide.com/types-of-fertilizer-spreaders/

Depending on the type, fertilizer can last for years in storage.  Liquid fertilizers can last upwards of 10 years, and granular fertilizer has no finite expiration date.  It isn’t just the chemical makeup of these products that affects their longevity – proper storage is key.

Effects of improper storage

Without proper storage, the most immediate impact is a complete loss of product.  This loss of product happens in a few specific ways:

• Caking/Clumping – When stored fertilizers are exposed to humidity, the granules clump together, creating a caking effect and greatly reducing a fertilizer’s flowability. Not only can this occur in warm temperatures, but it is also possible during colder seasons, due to the condensation that forms inside improperly sealed storage areas.
• Leaking and spills – Fertilizer shelf-life is further impacted by leaks and spills, which happen when fertilizer is not stored in the right conditions. Product can be lost to soil and water sources, which can also create danger for product contamination.
• Explosions and fires – Fertilizers that are placed near incompatible chemicals or flammable materials can cause combustion explosions and fires. This can result in loss of life, equipment, and facilities, in addition to product.

Despite these challenges, by using a handful of best practices, one can easily prolong fertilizer shelf-life and preserve its chemical strength and effectiveness.

Granular fertilizer is best preserved when stored indoors.

Best practices to extend fertilizer shelf-life

Though there are several different ways to store and protect fertilizer, there are three key steps every facility can take to get the best results.

Store fertilizer indoors

While there are currently some industrial solutions for outdoor fertilizer storage, including liquid fertilizer tanks and permanent storage tanks, both varieties are subject to extensive regulations and approval from government environmental agencies.  Therefore, indoor storage is the most economical and effective option.

Indoor storage also protects fertilizer product from exposure to UV rays and reduces the risk of freezing.  With UV exposure, some fertilizer granules can heat, which decomposes the nitrates contained within.  Decomposed nitrates produce nitrogen, carbon, and sulfur oxides, all of which weaken the product, and can cause fires and explosions if they’re stored near flammable materials.  Also, when frozen, chemical elements of the fertilizer can separate, further diluting its power.  There is a high probability that the fertilizer will not work as intended once it has thawed and then been reformed.

Indoor storage is therefore a far more effective way to extend fertilizer shelf-life.  However, it is important to ensure that the indoor conditions are ideal.  Among many aspects, facility managers must observe the following guidelines:

• Store fertilizer in an area that is not made of combustible material.
• Also, store fertilizer away from incompatible materials or chemicals. For example, if your facility manufactures urea and ammonium nitrate-based fertilizers, they must be separated to avoid a potentially lethal reaction.
• The fertilizer storage area must have proper ventilation.
• All fertilizer should be stored on a surface that’s dry, level, and free of any holes.
• Fertilizer should be stacked in such a way that it won’t collapse, i.e. limit height.
• Fertilizer should be stored away from the facility’s eaves and beams.

Store fertilizer in a low-humidity environment

Fertilizer is hygroscopic, which means it absorbs moisture from the air around it.  If the air surrounding the stored fertilizer is humid, then  water will be absorbed, thereby diluting and caking your product.  Simply keeping your fertilizer protected from outdoor conditions and precipitation is not enough.  Humidity poses one of the biggest threats to fertilizer shelf-life.  This threat looms during production, storage, transit, and bagging.

In addition to caking, humidity can zap fertilizer of its free-flowing properties as well as its physical, nutrient, and chemical properties.  It can even cause crystallization.  Not to mention, caked fertilizer can create numerous health hazards.  For example, large clumps can break off piles and fall on workers, harming them.  Or they can form in farmers’ storage bins, putting them in danger as they try to loosen clumps to move the fertilizer out of the bins.

To address this, air in the fertilizer storage space must be properly conditioned to stop the excess production of moisture.  The temperature must be regulated, hovering right around 81 degrees Fahrenheit and a relative humidity level between 30-40%.  Two solutions that achieve this regulated temperature are mechanical refrigeration and industrial-grade dehumidification.  The right solution(s) depends on the facility and its budget.

Use a protective coating

Lastly, one powerful way to protect fertilizer shelf-life is a protective coating.  Protective coatings can minimize caking and moisture pickup, control fertilizer dust, and even enhance flowability.  There are several types, including coating oils, particulates, polymer systems, and water-soluble liquids.

One such protective coating is MinTech’s Cake Brake, an anti-caking solution formulated to provide long-lasting anti-caking protection.  Cake Brake alters the interfacial surface tension between the treated granules, which stops crystallization and adhesion to surfaces.  It also prevents pile-set and bag-set during storage and transportation.

Additional best practices

In addition to the steps outlined above, it is also a great idea to use a pallet system, which helps avoid excessive stacking.  Also, put a good stock management system in place to ensure none of the fertilizer products stay stored for prolonged periods, and ensure the storage environment remains as hygienic as possible.

Fertilizer product is susceptible to a lot of environmental dangers both in the facility and as it goes through the latter stages of the manufacturing process.  These vulnerabilities can be controlled with the right processes in place.  Extend your fertilizer shelf-life with a few strategic moves.

Visit mintech.com/minterra to find out more about MinTech’s fertilizer dust control and anti-caking products.

During the entire fertilizer manufacturing process, including storage and bagging, fertilizer faces many threats that can impact its effectiveness and shelf-life.  One of the most dangerous problems is fertilizer dust.  Fertilizer dust can create health risks for facility workers, increase a facility’s potential for combustion fires, and lead to compromised product.  In short, without a fertilizer dust control solution in place, fertilizer dust can have substantial, long-term negative impacts for your facility.  Fertilizer dust control is a guaranteed way to protect product, mitigate risk, and protect your company’s bottom line.  It’s a smart and necessary investment for any facility.

Types of fertilizer dust control

Essentially, there are two primary ways to control fertilizer dust – collection and suppression.  Dust collection involves using a machine or system to capture and dispose of the dust.  Dust collection methods include exhaust hoods, duct systems, dust collectors, and fan or motor systems.  Though these options have some pros, they can be costly, their safety is very questionable, and there’s no universal standard governing these products.

On the other hand, dust suppression is a proactive solution that stops the flow and transport of dust before it becomes a problem that needs to be cleaned up.  Dust suppression uses one of four types of spray systems – water only, water-based, petroleum-based, and synthetic.  Dust suppression is the more effective fertilizer dust control option because it stops dust from becoming airborne and has a dust emissions reduction rate of 99% or higher.

So, it’s clear – dust suppression is the way to go.  But when selecting a fertilizer dust control option for your facility, it should accomplish the following five goals:

Five key components to look for

Maintain fertilizer integrity

Effective fertilizer dust control should ensure that your fertilizer product remains potent and powerful until it reaches the end user.  Often, this means it creates a coating around each granule that stops the flow of moisture from the atmosphere to the granule.  Fertilizer dust control shouldn’t break down or compromise any of the fertilizer’s key ingredients, and it shouldn’t change your fertilizer’s makeup in a way that makes it any less compliant with regulatory requirements.

All in all, it should stop the formation of dust, which will protect your workers, your facility, and your equipment.

Maintain fertilizer flowability

Fertilizer flowability is important.  This is a critical measure of a product’s accuracy and capability[1].  Ineffective fertilizer dust control might expose fertilizer to moisture and humidity, which reduces flowability and causes caking.  Caking sacrifices the quality and integrity of the product and also leads to chemical reactions and inadequate cooling.  Caked fertilizer is hard to handle and store, and it eventually spoils.

An anti-caking fertilizer dust control agent creates a protective barrier around each granule that keeps them separated.  Some fertilizer dust control agents are specifically designed to prevent caking.  But even in the event that a specific agent isn’t formulated for this purpose, it should never, under any circumstances, cause caking.

Flowability is key to fertilizer quality.

Handle dust control through multiple handling points

Fertilizer dust control should control dust for the life of the material.  It should work equally well during manufacturing, storage, transport, and bagging.  At no point should there be a sacrifice in quality.  A dust control coating should be applied once, and from that point, there should be little cause for worry or additional sprays.  Whereas dust collection is an ongoing process that must be regulated, dust control coatings can be used without disrupting or adding to current processes.

Keep costs economical

Fertilizer dust control should be economical.  Your facility shouldn’t see a major increase in expenditures to protect your product and your people.  Dust collection methods, which include the purchase and installation of bulky equipment and require consistent maintenance and monitoring, can be expensive and inconvenient.  When you consider the size and scale of a warehouse facility, it could take several units to adequately control dust.  Not to mention the additional costs to repair and maintain these units, plus training staff and dedicating manpower to the monitoring process.

By comparison, dust suppression is easier to use and doesn’t always require updates to the current structure and operation of your facility.  Quite often, the dust suppressants can be applied using an existing spray system, and if one is needed, a simple, small, cost-effective system can usually achieve the desired levels of dust control.

Provide on-going service

Not only do you need to consider a dust control solution’s performance and compatibility with your products; you also need to think about the company providing the solution and servicing your facility to be sure it is a good fit for your needs.  Fertilizer dust control is a key component of your product’s marketability, customer experience, and effectiveness, so finding a partner that understands your specific concerns and is willing to work with you on an on-going basis is of utmost importance.

Oftentimes, fertilizer dust control programs need lab tests and trials prior to beginning a relationship with a supplier, so look for a company that is willing to conduct these exercises at no-cost or at a reduced cost.  Be sure upfront that once the trials are complete, and the fertilizer dust control program is up and running, your partner is going to perform regularly scheduled maintenance visits and provide you with on-going field service reports to ensure the program is performing up to your quality standards.  A reputable, service-oriented partner is essential to the success of a fertilizer dust control program.

It is important to find a dust control partner that will provide on-going monitoring, service, and maintenance.

In conclusion, fertilizer dust control is an important investment for your facility that should not only prevent the spoiling of your product, but also make it stronger.  Before making an investment, you should research how the fertilizer dust control agent will impact your product’s integrity and longevity, and how those effects will apply across every touch point in the product’s lifecycle.  Additionally, you should find an option that provides on-going support and works with your facility’s budget and financial goals.

If you are looking to achieve all the above goals and more, MinTech offers several powerful fertilizer dust control coatings . MinTech’s MinTerra product line is an industry-leading suite of agents that are perfect for any facility and fertilizer type. To explore all MinTech’s fertilizer dust control solutions, visit mintech.com/minterra.

[1] Fulton, John and Port, Kaylee. (2019). Physical Properties of Granular Fertilizers and Impact on Spreading. Retrieved from: https://ohioline.osu.edu/factsheet/fabe-5501

In 2012, a study published in the journal Environmental Technology examined the impacts of fertilizer contamination from a phosphate plant on the east Mediterranean coast.  Due to local wind conditions, fertilizer dust spread across untreated areas, leading to soil pollution and creating potential hazards for groundwater sources and plant life (Kassier, Lartiges, and Ouaini, 2012)[1].  This is just one example of what can happen when facilities fail to institute proper fertilizer dust control procedures.  Not only can dust control help prevent harmful environmental effects, but it can also reduce hazards for workers and equipment.

The problems caused by fertilizer dust

A lack of fertilizer dust control leads to complications in four key areas: environmental impact, human health hazards, equipment breakdown, and dust-related explosions.

Unchecked dust in fertilizer processing facilities can lead to many issues.

As mentioned above, fertilizer contamination can negatively impact the environment.  It depletes soil quality and kills off both plant and aquatic wildlife.  This can potentially cause a shortage of fish, fauna, and flora, and it can lead to imbalances in the food chain, which can have far-reaching implications for food availability in local communities (Environment, 2015)[2].

Inside facilities, fertilizer dust can cause serious air quality issues.  Constant inhalation of toxic particles has wide-ranging effects but includes acute symptoms like nausea, vomiting, skin irritation, and chemical pneumonitis (RoboVent, 2019)[3], as well as chronic diseases like cancer and asthma.

Fertilizer dust can also coat, jam, and corrode equipment, which leads to more frequent upkeep or premature replacements.  And, the uncontrolled dust can mix with other chemicals, resulting in deadly dust combustion explosions (Lallanilla, 2013)[4].

Additionally, fertilizer dust can cause two major logistical headaches for production facilities.  The presence of fertilizer dust means product waste; wasted product can indicate reduced product quality.  There’s also reduced efficacy; a weakened product will perform poorly, and this could mean lackluster results for the end user, which means low crop yields and eventually a loss in sales.

So it’s clear, fertilizer dust control is a necessity.  But when it comes to choosing the best approach, which one is right for your business?

Dust collection

Dust collection involves using a system or machine to capture and dispose of fertilizer dust.

Example of a dust collection system

There are four primary types:

Exhaust hoods

Exhaust hoods are industrial versions of the hoods you find in residential home kitchens.  Once activated, exhaust hoods capture dust at a velocity that’s strong enough to pull the dust away from its usual trajectory.  Instead of blowing over workers or equipment, the dust is sucked into the hood.  These hoods are typically built to the specific needs of each facility, and installation of these systems requires a deep understanding of airflow concepts, such as capture velocity, transport velocity, and dust distance.

Duct system

A duct system works more like a vacuum.  It’s similar in appearance to the kind of duct system you’d find in a home or office building but it works at a superior level.  It’s based around either a flexible hose or a hard, fixed hose.  Flexible hoses are best for smaller facilities; hard, fixed duct systems are better suited for large ones.  Duct systems suck the contaminated air out of the building and pump clean air back into the space.

Fan/motor system

Fan/motor systems are commonly referred to as high-pressure blowers.   These machines come in a variety of sizes and blow the fertilizer dust away before it affects air quality.

Dust collectors

There are four different types of dust collector units on the market:

• Inertial separators: These units use centrifugal, gravitational, and inertial forces to remove fine dust particles that are suspended in air. Inertial separators can remove dust from gas as well.
• Fabric filters: These units are commonly used and come in many sizes. They filter dust and particulates from air or gas streams, but usually work as one component of a larger dust collection system.
• Wet scrubbers: These units use water to scrub dust particles from airstreams; they’re effective at reducing explosion potential.
• Electrostatic precipitators: These units use electrostatic force to pull in particle-polluted air. Then, they clean the air and pump out a clean airstream.  Electrostatic precipitators are composed of several elements, including a power supply, ionizing source, dust removal component, and an external enclosure.

Dust collection safety and efficacy

Though dust collection is popular and can be effective, it’s not always safe.  In 2015, the U.S. Chemical Safety Board found that, due to poor design and a frequent failure to test, dust collectors contributed to a high number of serious accidents (CSB, 2015)[5].  One such incident, a 2012 flash fire at a New Jersey plant, was caused by a dust collection system design failure; the system had only been in use for four days.

Concerning efficacy, there is no universally accepted standard for measuring industrial dust collector systems’ effectiveness.  The most common rating is the American Society of Heating, Refrigerating and Air-Conditioning Engineers’ (ASHRAE) MERV standard (NAFA, 2018)[6].  However, this standard was established for the industrial ventilation cleaning industry, not the fertilizer industry.

Standard 199, an effectiveness test for dust cleaning collectors and filters, was introduced in 2016 to combat the lack of regulation.  But to date, compliance with Standard 199 is voluntary (Kreczmer, 2017)[7].

Pros and Cons of Dust Collection

Dust collection has its share of benefits:

• There is a wide array of design options to suit facility needs.
• These dust collection options are capable of fine particle separation, they provide ventilation of heat and fumes, and the most effective designs achieve HEPA-quality filtration. (HEPA filters capture 99.97% of particles that are 0.3 microns.)
• Some NFPA-compliant dust collection models are available to ensure safer handling of combustible dusts.

However, despite these benefits, there are quite a few downsides:

• Many of these dust collection options are engineering-intensive and require lengthy design and installation processes.
• Because of these extensive processes, there are high initial costs and high ongoing energy costs.
• These options require a large physical footprint, and they’re difficult to retrofit into existing facility processes.
• Dust collection equipment requires routine service and maintenance which is often not supplied by the manufacturer.
• Any changes to your facility’s process will require system design changes and operational changes.
• Most units on the market are not NFPA-compliant and are prone to combustible dust explosions.
• Once dust is collected, it must still be handled and disposed of properly.

Dust Suppression

In contrast to dust collection, there’s dust suppression.  Instead of collecting and disposing of dust, dust suppression prevents dust in the initial stages.  Where dust collection is reactive, dust suppression is more proactive.

Dust suppression requires the use of spray systems.  Through these systems, spray nozzles are used to apply dust control agents directly to the fertilizers to prevent the dust from becoming airborne when being conveyed and transported.  The coatings mix with the dust particles; then the dust particles agglomerate together which weighs them down so they are returned to the ground or to their material source.  Depending on your facility operations, you may need to use dust suppression in conjunction with other prevention methods.

Example of a dust suppression system

There are four types of spray systems – water-only, water-based dust control agents, petroleum-based dust control agents, and with the introduction of MinTerra, a new line of coatings defined as synthetic dust control agents.

Water-only

Of the four spray system options available, a water-only system is the least effective.  This system adds a lot of moisture, which compromises the quality of the fertilizer and disrupts material flow.  There’s no physical barrier formed by use of water-only, there’s a poor coverage rate, and this product is prone to rapid drying.  There’s also no ionic charge, and there’s only a short-term trapping of fine particulates, which means constant spraying.  In fact, water-only spray systems have only shown an 80% effectiveness rate (Prostański, 2013)[8], which isn’t strong enough when product is on the line. Even if the amount of water used is restricted, adding moisture to the fertilizer begins to degrade the fertilizer before it makes it to the farmers’ fields, decreasing the overall yield and performance of the fertilizer. Any time moisture is added, it creates sticking and plugging of chutes and spreading equipment making it a material-handling nightmare. Not to mention, it can create a corrosive environment within the plant.

Water-based dust control agents

A water-based dust control system produces better results.  This method adds very little moisture to the dry fertilizer but improves the wetting of fine particulates. There’s also a slight physical barrier.  Water-based dust control agents and spray systems have an improved coverage rate, a slower drying time (which means longer dust control), cationic or anionic properties to attract dust particles, and short-term trapping of particulates. This method is best utilized when dust control is needed between the distributor and the fertilizer being spread in the field.

Petroleum-based dust control agents

Petroleum-based dust control agents are the best option for fertilizers used to date.  They add no moisture, reducing their effect on product quality and material flow.  They create a defined physical barrier and provide the best coverage rate.  Petroleum-based dust control agents are highly resistant to drying, which means long-term trapping of fine particulates.  As materials can be stored for months at a time before making it to the field to be applied, these agents are used in fertilizer manufacturing for long-term dust control. The key downside is most petroleum-based dust control agents require the product to be heated before being applied, which can add unnecessary costs and complicate manufacturing processes. In certain instances where a product requires heating before application, such as wax coatings, waxes can help maintain the integrity of the product and control dust up to a year once the wax creates a hardened shell on the fertilizer surface.

Synthetic dust control agents

Synthetic dust control agents are the latest technology for fertilizers coatings.  MinTerra DustAid Synthetic products are leading the way in transforming how fertilizer dust control agents are used in the industry. Like petroleum-based dust control agents, synthetics add no moisture, so they have little effect on product quality and material flow.  They, too, create a defined physical barrier, provide the best coverage rate, and are highly resistant to drying, making them ideal for fertilizers held in long-term storage.  The distinct advantage of synthetic dust control agents over petroleum-based agents is they do NOT need to be heated before being applied. They can be transported, stored, and applied at room temperature.  These products are low in viscosity, too, which simplifies the application system, requires fewer application points, but still provides long-term dust control, in many cases up to one year with a single application.

Pros and Cons of Spray Systems

Spray systems, in all varieties, have a slew of benefits:

• Dust is controlled, never airborne. It stays where it’s meant to be, which protects the quality of fertilizer products.
• There’s a low initial cost and low ongoing energy costs associated with application equipment.
• There’s a single application point.
• Service costs are included in the price of the system.
• There’s a small physical footprint since no extensive equipment installation is required; this is easy to retrofit into existing facility processes.
• Spray systems involve simple engineering, with a short design-fabricate-install-operate timeline.
• There’s a wide array of chemical options to treat all kinds of dust.
• Spray systems are highly effective, with a dust emissions reduction rate of 99% or higher.

There are a few negatives:

• The water and/or chemicals used in the spraying could damage process equipment or certain non-fertilizer materials.
• Water-based programs use high water volumes.
• There’s no service available for water-only programs.
• Chemical-based programs require storage and handling considerations, in addition to protocol already being followed for fertilizer.

When choosing a method for fertilizer dust control, it’s important to consider the needs of your product and facility.  However, between dust collection and dust suppression, dust suppression offers the strongest results and is safer, more affordable, and easier to incorporate.

Explore our dust suppression and coating options under our MinTerra line.  DustAid works with several types of fertilizer and is designed for effectiveness during the manufacturing, transportation, and application phases.  Learn more about DustAid here: https://mintech.com/minterra/dustaid/.

[1] Kassir, Lina Nafeh, Lartiges, Bruno, and Ouaini, Naim. (2012). Effects of fertilizer industry emissions on local soil contamination: a case study of a phosphate plant on the east Mediterranean coast. Retrieved from: https://www.tandfonline.com/doi/abs/10.1080/09593330.2011.601765?journalCode=tent20

[2] Environment. (2015). How Do Fertilizers Affect the Environment. Retrieved from: https://www.environment.co.za/environmental-issues/how-do-fertilizers-affect-the-environment.html

[3] RoboVent. (2019). Fertilizer Dust Collection. Retrieved from: https://www.robovent.com/dust-collection/fertilizer-dust-collection/

[4] Lallanilla, Marc. (April 18, 2013). What Causes Fertilizer Explosions? Retrieved from: https://www.scientificamerican.com/article/what-causes-fertilizer-explosions/

[5] CSB. (January 15, 2015). CBS Names Poor Design and Failure to Test Dust Collection System Among Causes of U.S. Ink New Jersey Flash Fire that Burned Seven Workers in 2012. Retrieved from: https://www.csb.gov/csb-names-poor-design-and-failure-to-test-dust-collection-system-among-causes-of-us-ink-new-jersey-flash-fire-that-burned-seven-workers-in-2012-osha-again-urged-to-issue-new-combustible-dust-regulations-/

[6] NAFA. (October 2018). Understanding MERV. Retrieved from: https://www.nafahq.org/understanding-merv/

[7] Kreczmer, Rick. (November 1, 2017). ANSI/ASHRAE Standard 199 improves industrial dust collection.  Retrieved from: https://www.ishn.com/articles/107521-ansiashrae-standard-199-improves-industrial-dust-collection

[8] Prostański, Dariusz. (2013). Use of Air-and-Water Spraying Systems for Improving Dust Control in Mines. Retrieved from: https://www.sciencedirect.com/science/article/pii/S2300396015300550

The fertilizer industry, which grosses $139 billion annually (The Fertilizer Institute, 2015)[1], faces a lot of modern challenges, from sustainability and regulatory hurdles to general worker safety.  But perhaps the industry’s biggest challenge is dust.  Dust-related problems can have a detrimental impact on worker health, product effectiveness, explosion risk, and the environment.  Finding a solution is critical for any fertilizer facility that wants to produce the best product and run a sound operation.

Dust build-up in plant presents safety hazards.

4 Common Dust-Related Problems

Though a failure to control dust can have a slew of negative effects, there are four key problems that have the potential to cause the biggest disruption.

Cross-contamination of fertilizers

One of the most concerning dust problems is drift, both inside the processing facility and during application.  Essentially, drift is the movement of fertilizer dust through the air (McAvoy, 2018)[2].  In the processing facility, fertilizer dust drifts into other products.  This can cause nutrient pollution, the effects of which won’t be felt during manufacturing but will become apparent after application.  With nutrient pollution (EPA, 2019)[3], the soil receives excess nutrition, and when it rains, the excess nutrients wash into nearby water sources, which could be home to plant or aquatic life, or could be the source of local drinking water.  There’s also drift after application, in which fertilizer dust drifts to untreated areas.  This can kill or severely damage other crops, resulting in low yields.

Product performance

Without proper fertilizer dust control, dust blows around the processing facility and ends up in other products, gets inhaled by workers, and clogs up machinery.  This is a two-fold problem – equipment will need to be repaired or replaced more often but, even more important, product will be lost.  It’s impossible to recoup the labor and material costs that went into producing a lost product.

Combustible dust

In some instances, dust buildup can lead to combustible dust explosions.  For example, in 2001, French agricultural chemical company AZF suffered a massive explosion at its Toulouse plant (CNN, 2001)[4].  240 people were injured and nearby areas had to be evacuated.  Combustible dust explosions are caused by a perfect storm of oxygen, heat, and a sufficient quantity and concentration of dust particles (OSHA, 2014)[5].  The enclosed space of a processing facility or factory adds in pressure, and the explosion occurs.

Health hazards

Inhalation of fertilizer dust can prove lethal for workers over time.  In 2000, two Florida women sued their former employer because their constant exposure to fertilizer dust had caused immune and respiratory system problems (Burstein, 2000)[6].  High nitrous oxide concentrations from fertilizer dust were linked to higher occurrences of childhood asthma in parts of California (Schlanger, 2018)[7]. And in general, studies have shown fertilizer dust has caused respiratory disease (Schenker, et al, 1998)[8] and acute symptoms like coughs and chest tightness (Rahman, Bråtveit, and Moen, 2007)[9].

Though these dust-related challenges can seem overwhelming and dangerous, there are some viable ways to put fertilizer dust control processes in place in your facility.

Solutions for Dust-Related Challenges

There are four primary ways to approach solutions for the serious dust-related challenges outlined above.

Robust facility hygiene practices

A pristine facility helps ensure that dust is controlled, product is protected, workers are safe, and your product poses no risk to the surrounding environment.  Your hygiene practices should include keeping fully stocked spill cleanup kits on hand and in easy-to-reach areas, cleaning up spills or leaks immediately, posting up-to-date hazard signage throughout storage areas, and keeping toxic chemicals separate in dry conditions.  The University of Massachusetts Amherst’s Greenhouse Crops & Floriculture Program hosts an extensive and printable checklist for fertilizer storage and handling best practices on its website.

Reduce the number of transfer points

A lot can go wrong at each transfer point in your facility.  A conveyer belt may not track correctly, which causes spillage of product.  Spillage can lead to spreading of product, which can contribute to workers’ slips and falls.  Spillage of product can also wear down equipment faster.  And the more points the product passes through, the more opportunity there is for dust.  If you reduce the number of transfer points in your facility, you also reduce the frequency and possibility of airborne dust.  But in addition to reducing transfer points, you should ensure the ones you keep are more effective.  This means working with an engineer to ensure conveyor belts track correctly, run smoothly, and prevent dust.

Use dust collection systems

Dust collection systems are designed to capture fertilizer dust.  There are four types: exhaust hoods, duct systems, fan/motor systems, and dust collectors.  Dust collection provides a lot of options to stop the flow of fertilizer dust.  For example, dust collectors alone have four different unit types.  But these systems aren’t regulated by a universal standard, which means facility safety and fertilizer dust control effectiveness can’t be guaranteed.

Use dust suppression methods

Dust suppression spray systems are the most effective fertilizer dust control option.  These systems employ spray nozzles, which apply moisture directly to the fertilizer dust particulates in the air.  The moisture weighs the particulates down, and they fall to the ground or return to their material source.

There are three types of spray systems – water, water and chemical combinations, and foam.  The most effective of the three is the foam spray system.  This combines water, chemicals, and air.  Foam sprays add the least amount of moisture to product, have the highest coverage rate, and dry slowly, which ensures long-term trapping of fine particulates.

In general, dust suppression spray systems control dust and keep it from being airborne.  The initial and ongoing costs are low, they’re easy to incorporate into your existing facility practices, they’re 99% effective, and there are several chemical options available.

One such option is DustAid, MinTech’s agricultural dust solution from our MinTerra product line.  DustAid coatings work in all phases of the fertilizer process – manufacturing, transportation, and application – and ensures dust control for the life of the targeted material.  Learn more about DustAid’s capability at mintech.com/minterra/dustaid/.

Fertilizer dust can wreak havoc in production facilities and on farms, with long-term negative impacts that can last for ages.  Proper fertilizer dust control is a must for any ethical fertilizer processing facility, and the best way to ensure total dust control is through a three-pronged approach of robust facility hygiene, fewer transfer points, and a strong dust suppression program.

[1] The Fertilizer Institute. (2015). State of the Industry. Retrieved from: https://www.tfi.org/sites/default/files/State_of_the_Industry_(ind._pages)_-_may_16_-_km_.pdf

[2] McAvoy, Gene. (May 14, 2018). CEU Series: How to Understand and Manage Pesticide Drift. Retrieved from: https://www.growingproduce.com/crop-protection/ceu-series-how-to-understand-and-manage-pesticide-drift/

[3] EPA. (2019). The Sources and Solutions: Agriculture. Retrieved from: https://www.epa.gov/nutrientpollution/sources-and-solutions-agriculture

[4] CNN.com/World. (September 21, 2001). French factory blast kills 17.  Retrieved from: http://www.cnn.com/2001/WORLD/europe/09/21/france.explosion/index.html

[5] OSHA. (2014). Hazard Alert: Combustible Dust Explosions. Retrieved from: https://www.osha.gov/OshDoc/data_General_Facts/OSHAcombustibledust.pdf

[6] Burstein, Jon. (February 23, 2000). Fertilizer Dust Hurt Health, Suit Says. Retrieved from: https://www.sun-sentinel.com/news/fl-xpm-2000-02-23-0002230170-story.html

[7] Schlanger, Zoë. (January 31, 2018). We knew fertilizer contaminates water. It turns out it contaminates air, too. Retrieved from: https://qz.com/1194589/weve-been-severely-underestimating-a-dangerous-type-of-air-pollution/

[8] Schenker, Marc B., et al. (November 1, 1998). Respiratory Health Hazards in Agriculture. Retrieved from: https://www.atsjournals.org/doi/full/10.1164/ajrccm.158.supplement_1.rccm1585s1

[9] Rahman, Hamidur, Bråtveit, Magne, and Moen, Bente E. (2007). Exposure to Ammonia and Acute Respiratory Effects in a Urea Fertilizer Factory. Retrieved from: https://www.tandfonline.com/doi/abs/10.1179/oeh.2007.13.2.153

Fertilizer manufacturers ultimately want to produce the best possible product – fertilizer with high production yields, high material integrity and quality, and strong marketability. But the manufacturing process leads to other concerns and challenges. Manufacturers must also reduce explosion potential in their facilities and reduce their workers’ exposure to toxins, which means pristine facility hygiene. All of these goals can be achieved through fertilizer dust control.

Dusting of fertilizer at various points in manufacturing, transporting, and storage can cause many issues from equipment wear to higher probability of explosions.

Why fertilizer dust control matters

Without dust control, the fertilizer manufacturer faces a lot of potential liability, danger for workers, and loss of product and equipment. Not to mention, fertilizer dust-related problems could cause damage to the manufacturer’s reputation within the industry.

On one end, a lack of fertilizer dust control can have minimal effects.  A processing facility might need to invest in more frequent maintenance and upkeep of machinery or purchase new machinery more frequently. This means unnecessary expenditures when these funds could be used elsewhere in the business.

But a lack of dust control can have more detrimental effects.  Prolonged, unmitigated exposure to toxins could result in illness or disease for workers.  A study published in the American Journal of Industrial Medicine (Daniels, Dunn, Kubale, Stayner, & Yiin, 2016)[1]found that workers continuously exposed to various chemical elements at a phosphate fertilizer plant had higher rates of lung cancer and emphysema.  Poor dust control can even lead to disaster.  The 1947 Texas City, Texas blast was the deadliest industrial accident in American history (Lallanilla, 2013)[2], and it was caused by improper handling of ammonium nitrate, which is a key ingredient used to improve fertilizer’s nitrogen content.  More recently, a 2013 fire at an ammonium nitrate storage and distribution facility in West, Texas killed 15 people (EPA, 2015)[3]and even damaged nearby businesses, homes, and schools.

1947 Texas City, Texas explosion at an ammonium nitrate plant had blasts so strong they shattered windows 40 miles away in Houston.

Fertilizer dust control isn’t just a way for processing facilities to save money; it can also save lives.

The benefits of dust control

Dust that’s produced during material processing operations becomes a major source of harm and environmental pollution.  This isn’t just in the processing facilities; it’s also a concern at the mining stage and even during shipping and storage.

Fertilizer dust control can mitigate risk at every stage of the production process:

• It protects granule integrity during storage.
• It ensures fertilizer doesn’t become too fragile, which prevents deterioration.
• It reduces risk of fire and dust explosion.
• It boosts safety for all workers and improves on-site visibility.
• It prevents unpleasant odors.
• It reduces the need for, and cost of, maintenance and cleaning.
• It slows wear and tear on equipment.
• It cuts down on wasted product.
• And, it creates a healthier workplace, which in turn improves worker morale and boosts both production and the quality of work.

Some facilities aren’t taking the proper actions, mistakenly thinking they can continue on business as usual or refine select parts of their production processes.  But other companies have turned to regular dust control coatings because they’re long-lasting, they minimally impact the treated fertilizer’s flowability, and they make day-to-day operations safer and more economical.  Even better, fertilizer dust control helps facilities and farmers alike ensure compliance with federal regulations.

Essential regulations for every fertilizer processor

In addition to worker safety and protecting the environment, dust control coatings help with compliance with a slew of regulations from the Environmental Protection Agency (EPA), Occupational Safety and Health Administration (OSHA), and Mine Safety and Health Administration (MSHA).  There are several regulations, and it’s recommended that all fertilizer manufacturers and farmers read them in full, but some of the most important ones to note are as follows.

EPA

• For facilities that handle more than a threshold quantity of certain toxic and/or flammable substances, they’re required to have a Risk Management Program and Plan (RMP) in place. The RMP must be submitted to the EPA for approval.  This plan covers everything from a prevention program and risk management plan to an emergency response program and plans for communication with the public in the event of an accident or emergency (EPA, 2019)[4].
• Each fertilizer facility and all farms must adhere to the General Duty Clause, which essentially states that any business handling hazardous chemicals has a duty to identify potential hazards and take steps to ensure safety for workers and surrounding communities (EPA, 2009).[5]
• Fertilizer facilities must follow the Emergency Planning and Community Right-to-Know Act (EPCRA), which was created in 1986 and requires facilities to report the storage and handling of hazardous materials to federal, state, and local governments (EPA, 2019)[6].
• Some farms are subject to the Clean Air Act, which monitors the release of certain pollutants into the environment and regulates air quality (EPA, 2019)[7].
• EPA also offers guidance and research specific to different types of fertilizer (EPA, 2019)[8]. For example, for fertilizers made from recycled wastes, there are limits for the amount of heavy metals or toxic compounds that can be included in these products.

OSHA

In conjunction with the EPA, OSHA has pulled together an exhaustive list of resources about handling fertilizer.

• There are several regulations about the safe storage, handling, and management of solid ammonium nitrate prills (EPA, OSHA, 2015)[9]. For example, AN prills can’t be heated in a confined space, they can’t be exposed to strong shock waves from explosives, and they can’t be contaminated with combustible materials or organic substances.

Concerning the storage of ammonium nitrate, OSHA goes deep into the innerworkings of processing facilities (OSHA, 2019)[10]:

• Floors must be constructed to eliminate floor drains and piping, to keep out molten materials that could flow or be confined during a fire.
• Facilities must regularly clean floors and equipment as well as the entire plant.
• The land surrounding a mixing plant must be kept clear of brush, dried grass, leaves, and other flammable shrubs for 25 feet.
• Facilities must dispose of AN bags in a safe manner.
• Explosives can’t be used inside of or within 50 feet of a facility that’s used for mixing blasting agents.

MSHA

MSHA focuses many regulations on the proper handling of hazardous chemicals and protection of workers doing the handling.

• Facilities must inform miners about chemical hazards. This involves inventorying chemicals at the mine, determining the hazardous ones, keeping an updated list, writing out a hazard program, and properly labeling hazardous chemicals with accurate Material Safety Data Sheets (MSHA, 2002).[11]
• The MINER Act requires Mine Emergency Response Development (MERD) exercises at least twice per year, to ensure that emergency plans are adequate and officials can act swiftly in the case of a real emergency (MSHA, 2009).[12]
• Mining companies are also obligated by law to maintain the lowest possible personal dust exposure limit for miners (MSHA, 2009).[13]

In short, fertilizer dust control is a necessary part of any fertilizer processing facility’s operations, as it helps company efficiency, ensures worker safety, and fosters the creation of a stronger product for farmers.  The EPA, OSHA, and MSHA regulations further illustrate why dust control and proper handling of hazardous chemicals is so important.

If you’re not sure where to start with fertilizer dust control for your facility, look to DustAid from MinTech’s MinTerra product line.  DustAid coatings were designed to control dust during manufacturing, transportation, and application stages, and they reduce dust on a wide variety of fertilizer blends.  To find out more about DustAid, visit https://mintech.com/minterra/dustaid/.

[1]Daniels, R. D., Dunn, K. L., Kubale, T. L., Stayner, L. T., & Yiin, James H. (2016). A Study Update of Mortality in Workers at a Phosphate Fertilizer Production Facility. Retrieved from: https://www.ncbi.nlm.nih.gov/pmc/articles/PMC4913354/

[2]Lallanilla, Marc. (2013). What Causes Fertilizer Explosions?Retrieved from: https://www.scientificamerican.com/article/what-causes-fertilizer-explosions/

[3]Environmental Protection Agency. (2015). Chemical Advisory: Safe Storage, Handling, and Management of Solid Ammonium Nitrate Prills. Retrieved from: https://www.epa.gov/sites/production/files/2015-06/documents/an_advisory_6-5-15.pdf

[4]EPA. (2019) Risk Management Plan (RMP) Rule. Retrieved from: https://www.epa.gov/rmp

[5]EPA. (2009). The General Duty Clause. Retrieved from: https://www.epa.gov/sites/production/files/2013-10/documents/gdc-fact.pdf

[6]EPA .(2019). Emergency Planning and Community Right-to-Know Act (EPCRA). Retrieved from: https://www.epa.gov/epcra

[7]EPA. (2019). Summary of the Clean Air Act. Retrieved from: https://www.epa.gov/laws-regulations/summary-clean-air-act

[8]EPA. (2019). Agriculture Nutrient Management and Fertilizer. Retrieved from: https://www.epa.gov/agriculture/agriculture-nutrient-management-and-fertilizer

[9]EPA, OSHA. (2015). Chemical Advisory: Safe Storage, Handling, and Management of Solid Ammonium Nitrate Prills. Retrieved from: https://www.epa.gov/sites/production/files/2015-06/documents/an_advisory_6-5-15.pdf

[10]OSHA. (2019). 1910.109 – Explosives and blasting agents. Retrieved from: https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.109

[11]MSHA. (2002). Telling Miners About Chemical Hazards. Retrieved from: https://arlweb.msha.gov/REGS/COMPLIAN/GUIDES/Hazcom/HazComToolKit.pdf

[12]MSHA (2009). Mine Emergency Response Development (MERD) Contest Guidelines. Retrieved from: https://arlweb.msha.gov/REGS/COMPLIAN/GUIDES/MERDGuidelines062009.pdf

[13]MSHA (2009). Questions and Answers, MSHA’s Final Rule on Conveyer Belt, Fire Prevention and Detection, and Use of Air From the Belt Entry. Retrieved from: https://arlweb.msha.gov/REGS/COMPLIAN/GUIDES/BeltAir.pdf

MinTech chemists have conducted extensive tests to see if using our DustNot Syn product is as effective at curing the biomass pellet ails as it is the coal.  Spoiler Alert: It is.

Biomass pellet dust at vibratory feeder – before and after treatment

Here are the four common issues faced by biomass pellets:

1. The dried material is inherently dusty due to its organic powder/fiber composition
2. Angularity and high coefficient of friction (sCoF) causes abrasive and erosive material flow
3. Supply chain of biomass pellets has multiple transfers, each creating more and more dust
4. Biomass pellets are extremely absorbent, gaining moisture from the air, rain, snow, etc.
   • Reduction in caloric heat value (btu)
   • Degradation of pellet strength (most biomass binders are water-soluble)
   • Increased weight increases shipping costs

Watch the video below for a look at how much dust was generated at one transfer point in our field study prior to the application of DustNot Syn.  Keep this in mind because you’ll see the results at the bottom of this post.

MinTech set out to address each of these issues, first in the lab and then in the field, using DustNot Syn.  DustNot Syn is a synthetic, petroleum-free, food-grade dust control agent, made with proprietary technology.  The benefits of the product are numerous:

• Provides residual dust control for up to 180 days
• Operating temperature from -40°C to +60°C (-40°F to +140°F)
• Designed for water-sensitive materials like lignin, cellulose, wood, and fertilizer
• Environmentally responsible
  • Petroleum-free, metal-free,
  • No VOCs (volatile organic compounds)
  • Non-toxic, non-corrosive, non-flammable
  • Odorless, colorless, food-grade, and allergen-free
  • No phosphates, chlorides, EDTA, APE, or NPE compounds
• Non-leaching, and provides a clear, water-resistant coating to pellets
• Non-filming, non-crusting, and never dries out
• No ash or emission concerns at power stations – has been used to treat coal, limestone, pet coke, and other fuels
• High BTU value of 140,000 Btu/gallon (142,425 kJ)
• Provides lubricity to pellets, reducing friction, improving flow, and reducing degradation

Our preliminary lab tests showed that DustNot Syn reduced dust by 95%.

Photo of third-party preliminary lab test results.

We then took the product to the field and tested six different application methods to determine the optimum process to achieve the highest, most consistent level of control.  The results are in:

• DustNot Syn provides a 90% reduction in dust
  • Degree of control dependent upon treatment rate and application technique
• DustNot Syn protects biomass pellets from moisture ingression
  • Untreated biomass pellets absorbed 5X more water than treated pellets
• DustNot Syn’s performance improves with multiple transfers of pellets
• DustNot Syn controls dust for at least 45 days

Now watch this video of just how much dust was abated by the use of DustNot Syn at transfer.  That’s what I call results!

To download the full study, click here.

If you are interested in learning more about how MinTech can help you with your biomass process, please contact us.

This blog post is part two of a three-part series on spontaneous coal combustion.  In this post, we focus on preventative measures and controls, and in the upcoming post we’ll take a look at best practices. Click Here to Read Part 1: A Burning Mystery to review history and research on the topic.

Anyone who has worked with Powder River Basin (PRB) coal knows how susceptible it is to spontaneous combustion. It is not a matter of if it will catch fire, but when. With so many coal-fired power plants switching to PRB coal due to its low-sulfur properties to meet tighter emission regulations, many utilities are facing newer storage and handling challenges, with fires being a primary concern. Thus, early detection and prevention of spontaneous coal combustion is of great value to industry.

What is being done to find a solution to this burning problem?

The industrial revolution was responsible for the coal industry boom in the early 1900s as society was introduced to electricity, new industrial technologies, and a rapid increase in steel demand. Companies were expanding the size of their factories, employing more workers, and using more machinery, marking great progress in mass production. Electric power was rapidly replacing steam power because it was cheaper, faster, and more flexible for factories to operate. This caused a significant spike in coal consumption, leading to more and more documentation of spontaneous coal fires in mines, on trains, and in coal-fired power plants and steel mills.

Early research studies of coal oxidation identified several key parameters that influence the process, such as coal rank, particle size, and surface area, and they showed the influence of moisture on spontaneous heating. It was concluded that coals with high moisture content have pores filled with water that cannot absorb oxygen, making them less likely to spontaneously combust, whereas dried coals will absorb moisture from the environment, releasing the heat of condensation, and increasing critical temperature, making them more susceptible to spontaneous combustion. These learnings have led to several procedural changes and mechanism designs that allow the industry to more safely store, transport, and handle PRB coal, but there is still a lot of room for improvement.

Earliest forms of inhibitors

Coal mines, coal trans-loading terminals, coal-fired power plants, and all industries involved in the transport of coal (i.e. rail, barge, and truck) are investing in more research to improve safe handling of the material.  Researchers agree oxidation plays a major role in spontaneous combustion, which means it can be prevented through physical or chemical modifications in order to prevent thermal runaway.

Coal is a complex, chemically reactive material.  This makes selecting chemical

inhibitors rather challenging.  MinTech has been involved in the research and development of spontaneous combustion inhibitors for nearly a decade.  We’ve worked alongside other researchers in the industry to test various compounds in an effort to determine the most cost-effective solutions.  The incorporation of various inorganic compounds, such as readily available industrial salts, into coal has been found to create several subtle physio-chemical reactions that work in concert to inhibit spontaneous combustion. The general concept is to prevent self-heating of coal by creating an oxidative barrier on the coal surface.

Salts such as sodium chloride, magnesium chloride, calcium chloride, calcium carbonate, sodium phosphate, sodium sulfite, and sodium sulfate improve the thermal stability of coal, reducing the rate of spontaneous combustion. These inhibitors make active oxidation sites inert in three ways:

1. They adsorb water from the atmosphere, which blocks active oxidation sites
2. They promote polymerization and cross-linking through ester bond formation
3. They behave as antioxidants that scavenge free radicals, forming stable oxygenated complexes

Lab studies and field studies have shown a significant correlation between the application of chemical inhibitors and a reduction in spontaneous combustion events.  Furthermore, the data supports the treatments not only inhibit spontaneous combustion, but also preserve overall Btu value.  There is one drawback, though.  These conventional salt-based inhibitors fail to take into account the environmental impact of adding such salts to coal.  Chlorides and sulfur are classified as HAPs (Hazardous Air Pollutants) and are tightly regulated by the EPA.  The addition of salt-based inhibitors would require coal-fired power plants to add steps to their processes to remove the HAPs in order to maintain compliance, which in turn adds cost.

Fortunately, material handling solutions providers, such as MinTech, have developed environmentally responsible inhibitors that utilize anti-oxidant chemistries (without the salt) to provide the effective spontaneous combustion prevention needed without adding any HAPs that then need to be scrubbed to obtain emissions compliance.

For example, CoalTrol F65 is a full body feed process dust suppressant combined with our spontaneous combustion inhibitor technology. This solution incorporates the technology of our Flame Freeze anti-oxidant chemistry, which directly interrupts the oxidation and combustion process to eliminate spontaneous coal fires. This product can be utilized at all stages of the material handling process to control spontaneous combustion and suppress dust with minimal effect on BTU value, without increasing ash content or increasing NOx, sulfur, chlorides, or other HAPs.

 Another example is Mincryl X50, our premier coal pile sealant and bunker sealant, which protects coal from moisture and oxygen exchange, reducing overall heat formation. The solution also keeps the coal from deteriorating, helping maintain BTU values and allowing it to burn more efficiently. Plus, if you’re sealing a storage pile, you have the added benefit of controlling fugitive and windblown coal dust and eliminating pile erosion.

How can inhibitors be used in preventative methods?

Full-body treatments

Facilities responsible for handling subbituminous coals, such as PRB coal, can apply chemical inhibitors at transfer points to retard spontaneous combustion in trains, on barges, in storage piles, and in coal yards. Inhibitors are sprayed at transfer points to evenly treat the full body of the coal stream as it tumbles down and is spooned onto the next conveyor. This allows for maximum coverage to prevent fires from occurring up to 60 days, depending on the product, application rate, and desired retardation.

One coal fired power plant MinTech treated in Arizona had 1-2 fires in their coal yard every day. Once a full-body treatment program was implemented, treating the coal being unloaded at stackout, the incidents decreased to only one hot spot every 15-20 days. That’s an 85% reduction in the number of coal fires in the coal yard.

If a power plant has a problem with hot spots entering their power plant, the coal can be treated with a two-in-one dust suppression and spontaneous combustion product. The solution is applied as a foam to achieve maximum coverage and to control dust through as many as four transfer points; however, the product will also put out hot spots, reducing the risk of fire, or worse, a dust explosion (especially in bunkers).

Coal Pile Sealants

With lower demands for coal in the US over the years, many coal-fired power plants end up storing larger volumes of coal, increasing the probability of a spontaneous combustion event. Not only are fires a concern, but so is dust, wet coal, deterioration in coal quality (decreased BTU content), and erosion. A key method of maintaining coal quality is to seal piles against moisture exchange and oxygen. Sealing coal piles helps to control dust, limit erosion, and lengthen the shelf-life of coal by maintaining BTU value.

By applying a coal pile sealant, you can prevent coal oxidation and moisture exchange, lowering the possibility of spontaneous coal fires too. The pile sealant alters the balance of heat generated and encourages the dissipation of heat to prevent heat accumulation and slow the oxidation rate. Pile sealant applications can also be performed on a smaller scale as in-transit rail car topper treatments and barge sealing treatments.

Bunker Sealants

Coal fired power plants for some reason or another may experience an unexpected shutdown. When this happens, coal is left in bunkers inside the plant, which can be problematic since most coal is susceptible to spontaneous combustion. It is typically very difficult to have the coal removed from these bunkers, meaning a fire hazard will be sitting in the facility for an unknown amount of time. Therefore, the best practice is to seal these bunkers with bunker sealants. The idea is similar to coal pile sealing in that it prevents coal oxidation and moisture exchange from occurring, mitigating the risk of a spontaneous coal fire or the formation of hot spots.

How does MinTech stand out in spontaneous combustion inhibition?

Since its inception in 1998, MinTech has worked alongside mining, rail, steel, and power industries developing new solutions and best practices for managing spontaneous coal fires. The R&D team, headquartered in Atlanta, GA, has been working to advance chemical inhibitor research and coal pile management to control spontaneous fires and maintain coal quality.

Through our work designing customized treatment programs relevant to our customers’ unique projects, we came across a need for combination treatments that would solve more than one issue with a single solution.  We now offer several “two-in-one” dust control and spontaneous combustion inhibitors and even “three-in-one” dust control, freeze conditioning, and spontaneous combustion inhibitor treatment solutions. These dynamic products allow for a single application system to apply a single chemical to achieve multiple goals.  This is attractive to existing operations because MinTech can utilize current dust suppression spray systems and simply make minor modifications to make them suitable for applying a multi-functional product.  It’s also attractive to new operations as they are able to reduce the footprint required for dust suppression, freeze conditioning, and spontaneous combustion inhibition by half or even two-thirds.

MinTech’s recipe of quality products, high-performance equipment, and full-service installation, operation, and service has provided customers peace of mind when it comes to handling coals susceptible to spontaneous combustion.  If you’re interested in learning more about how we can help you, contact us.